I appreciate all feedback on these screen surrounds, and if something is wrong I will do my best to fix it.
I have tested the screen size on about 10 gameboy cases so far, and a couple were tight, only as much to fit without glue. There wasn't any bending or bowing. Having said that, I have a suspicion that there may be a slight variation in the laser cut screens, like less than 0.1mm overall.
Yes they are thicker, but are the same thickness as the glass screens.
About the glass screens, well the first ones I bought had like a bubble spot in the corner that interfered with the decal. So I have bought more glass screens and now found that it is difficult to apply the decal

. I am going to try a different method, it is not an easy thing to make!
Cheers,
Dom.